Toner filling apparatus including an anti-dribbling nozzle having air discharge ports

ABSTRACT

Apparatus has been provided for directing toner from a hopper containing a supply of toner to fill as well as cleanly cutoff filling of a container without post-cutoff dribbling. The apparatus includes (a) a conduit member connected to the hopper and having a discharging end for permitting a toner to be moved therethrough; (b) a conveyor device located at least partially within the conduit member for moving the toner from the hopper in a toner moving direction towards the container; and (c) an anti-dribbling nozzle device for directing the toner from the conveyor to cleanly fill the container. The anti-dribbling nozzle device includes a source of pressurized air, a controller, and a nozzle member that has a first end connected to the discharge end of the conduit member, a second and opposite end for dispensing moving toner into the container, and a nozzle wall connecting the first end to the second thereof. The nozzle wall includes slanted air discharging ports for discharging directed pulses of positive pressure air to forcibly remove powder from the nozzle wall, thereby enabling clean cutoff of powder flowing into the container without post-cutoff dribbling.

RELATED APPLICATION

[0001] This application has the same inventor as, and is a Divisionalof, U.S. application Ser. No. 10/198,398 filed on Jul. 17, 2002.

BACKGROUND OF THE INVENTION

[0002] This invention relates generally to apparatus for filling acontainer with dry particulate material, and more particularly concernsa filling apparatus including an anti-dribbling filling nozzle havingslanted air discharge ports for achieving dribble-free, clean-cutofffilling of a container with particulate materials such as toner.

[0003] Currently when filling particulate materials, for example tonersinto toner containers, toner is transported from the toner supply hopperinto the container by a rotating auger. The auger is a spiral shapedmechanical part which pushes particles of toner inside a fill tube bydirect mechanical contact. The nature of this mechanical contact processcreates substantial limitations on accuracy and productivity of thetoner filling operation. The speed of the toner movement in the filltube is proportional to the speed of rotation of the auger and islimited by heat release due to auger/toner/funnel friction.

[0004] Toner containers for small low cost printers and copierstypically have a small opening into which the toner is to be added.Furthermore, the toner containers often have irregular shapes to conformto the allotted space within the copying machine. Therefore it becomesdifficult to fill the toner container because of the small tube ornozzle required to fit into the small toner container opening andsecondly for all the toner within the container to completely andcleanly fill the remote portions of the container before the containeroverflows.

[0005] In addition, during the filling operation there is someordinarily undesirable continued discharge of toner (dribbling) from aconventional nozzle at cutoff or at the end of the filling cycle. In oneembodiment, the end of a filling cycle occurs when the auger stopsrotating and positive pressure normal to the axis of the auger is kepton for a fraction of a second longer in order to give some time for thetoner or powder remaining in the nozzle to drop into the container.After that, the positive pressure is cut off and negative pressure inthe form of a vacuum is turned on to “freeze” against the nozzle wall,any toner particles still remaining in the nozzle.

[0006] The main problem with this process is that when the positivepressure in the nozzle is switched to vacuum, this vacuum usually canfirmly hold only a 3-5 mm thick layer of toner particles against theinner nozzle wall. Therefore in cases where the amount of tonerremaining inside the nozzle is sufficient to create a layer thicker than5 mm, the force of vacuum will be marginal (weak) for holding thosetoner particles on the top of the 5 mm layer surface. Thus, very oftenthis force is not enough to hold them for more than 0.5-1 sec.Therefore, undesirable post-cutoff continued toner fallout or dribblingoccurs when the filling apparatus indexes from one container to thenext, thus resulting in dirty tops and/or sides of containers.

[0007] Conventional filling apparatus include conventional clean fillingsystems for use with such apparatus. Such a clean filling system issecured to filling line as well as to the toner conduit, and may be usedto support a slide. The slide is connected to a tray or toner drip platewhich slidably is fitted between the nozzle and the opening. A tray ordrip plate in this position acts to prevent the spilling of powderduring the indexing of containers. A housing which surrounds part of thenozzle, provides a cavity or chamber which is sealed when the tray ordrip plate is in its closed position.

SUMMARY OF THE INVENTION

[0008] In accordance with the present invention, there is provided amethod and apparatus for directing toner from a hopper containing asupply of toner to fill as well as cleanly cutoff filling of a containerwithout post-cutoff dribbling. The apparatus includes (a) a conduitmember connected to the hopper and having a discharging end forpermitting a toner to be moved therethrough; (b) a conveyor devicelocated at least partially within the conduit member for moving thetoner from the hopper in a toner moving direction towards the container;and (c) an anti-dribbling nozzle device for directing the toner from theconveyor to cleanly fill the container. The anti-dribbling nozzle deviceincludes a source of pressurized air, a controller, and a nozzle memberthat has a first end connected to the discharge end of the conduitmember, a second and opposite end for dispensing moving toner into thecontainer, and a nozzle wall connecting the first end to the secondthereof. The nozzle wall includes slanted air discharging ports fordischarging directed pulses of positive pressure air to forcibly removepowder from the nozzle wall, thereby enabling clean cutoff of powderflowing into the container without post-cutoff dribbling.

BRIEF DESCRIPTION OF THE DRAWINGS

[0009] In the detailed description of the invention presented below,reference is made to the drawings in which:

[0010]FIG. 1 is an elevational view of a toner container fillingapparatus partially in section utilizing an anti-dribbling nozzle devicehaving the slanted air discharge ports in accordance with the presentinvention;

[0011]FIG. 2 is an elevational view of an enlarged portion of thefilling apparatus of FIG. 1 showing the anti-dribbling nozzle devicehaving the slanted air discharge ports in accordance with the presentinvention;

[0012]FIG. 3 is an elevational view of the anti-dribbling nozzle deviceof FIG. 2 during container filling;

[0013]FIG. 4 is an elevational view of the anti-dribbling nozzle deviceof FIG. 2 during cutoff of container filling; and

[0014]FIG. 5 is an elevational view of the anti-dribbling nozzle deviceof FIG. 2 post-cutoff showing a clean cutoff without dribbling inaccordance with the present invention.

DETAILED DESCRIPTION OF THE INVENTION

[0015] While the present invention will be described in connection witha preferred embodiment thereof, it will be understood that it is notintended to limit the invention to that embodiment. On the contrary, itis intended to cover all alternatives, modifications, and equivalents asmay be included within the spirit and scope of the invention as definedby the appended claims.

[0016] According to the present invention and referring now to FIG. 1,powder filling apparatus 10 is shown. The powder filling apparatus 10 isused to convey powder 12 in the form of toner for use in a copier orprinter from a hopper 14 to a container 16. The powder filling apparatus10 is mounted to filling line 20 to permit for the filling of largeproduction quantities of containers 16, the container 16 is mounted to acarrying device 22. The device 22 is movable in the direction of eitherarrow 24 or 26. The carrying device 22 serves to position containercenterline 30 in alignment with apparatus centerline 32.

[0017] The powder filling apparatus 10 includes an anti-dribbling nozzle34 (in accordance with the present invention, and to be described indetail below) which is used to direct the powder 12 into the container16. The anti-dribbling nozzle 34 is connected to the hopper 14 by meansof a conduit 36 in the form of a hollow tube or funnel. As shown in FIG.1, the hopper 14 is positioned above the container 16 whereby gravitywill assist in the flow of powder 12 toward the container 16. Tooptimize the flow of powder 12 toward the container 16, the powderfilling apparatus 10 further includes a conveyor 40 positioned at leastpartially within the conduit 36 for assisting in the flow of the powder12. The conveyor 40 is in the form of a spiral conveyor or auger. Forexample, the auger 40 may be in the form of a spiral shaped auger, whichmay include various geometries, such as, a straight or tapered helicalscrew. The auger closely conforms to the conduit.

[0018] The anti-dribbling nozzle 34 is insertable into opening 42 of thecontainer 16. The insertion of the anti-dribbling nozzle 34 in theopening 42 may be accomplished in any suitable method. For example, thecarrying device 22 and, consequently, the container 16 may be movableupward in the direction of arrow 44 for engagement with theanti-dribbling nozzle 34 and downward in the direction of arrow 46 fordisengagement from the opening 42. The upward and downward motion of thedevice 22 and the container 16 permits the container 16 to be indexed inthe direction of arrows 24 and 26.

[0019] To permit the filling of a number of containers 16, the flow ofpowder 12 from the hopper 14 must be halted by cutting off filling orpowder flow, during the indexing of a filled container 16 from the fillposition and during the indexing of the unfilled container 16 toward thefilling position. In accordance with the present invention, it isimportant that halting powder flow by cutting off filling or powder flowbe achieved cleanly without significant or any post-cutoff continuedflow or dribbling.

[0020] As shown in FIG. 1, the auger 40 may be rotated by any suitablemethod, i.e. by motor 50 connected to the auger 40 for rotating theauger 40 in a direction 53. The motor 50 is connected to a controller 52which sends a signal to the motor 50 to stop the rotation of the auger40 during indexing of the carrying device 22. The controller 52 is alsoconnected by means 54 to the source 66 of pressurized air for varyingthe application of positive air pressure from a uniform pressure 68 toshort bursts of higher pressure air 70. Accordingly, the primary flow ofpowder 12 is halted by the stopping of auger 40 within the conduit 36and by the use of a valve therein (not shown). A housing 56 whichsurrounds part of the anti-dribbling nozzle 34, provides a cavity orchamber 62 which is sealed when the discharge opening 94 of the nozzle34 is closed by suitable means (not shown). The chamber 62 can bepressurized or kept under vacuum via an air pressure applying device 64that can apply uniform positive pressure 68 (FIGS. 2 and 3) as during afilling cycle, short bursts of higher positive pressure 70 fordribble-free cutoff in accordance with the present invention, ornegative pressure 69 (FIGS. 4 and 5) post-cutoff. As shown in FIG. 1,the device 64 can also be a toner dust vacuum line 64 to an air pressureand vacuum source 66.

[0021] Referring now to FIGS. 1-2, the anti-dribbling nozzle 34 is shownin greater detail and includes a first end 90 adjacent to and mounted tothe conduit 36, as well as a second end 92 opposed to the first end 90.The anti-dribbling nozzle 34 is comprised of a wall 96 and is secured tothe conduit 36 in any suitable fashion. For example, as shown the firstend 90 of the anti-dribbling nozzle 34 may be press fitted over theconduit 36 and is rigidly located within the housing 56. Between thefirst end 90 and the second end 92 of the anti-dribbling nozzle 34 is acentral portion 93 of the nozzle. The central portion 93 has a hollowsubstantially conofrustrical shape or funnel like shape. As shown, thesecond or discharge end 92 includes a discharge opening 94 defined bythe wall 96.

[0022] Thus to recap, in accordance with the present invention, there isdisclosed an apparatus 10 for directing powder 12 from a hopper 14containing a supply of powder to fill as well as cleanly cutoff fillingof a container 16 without post-cutoff dribbling. The apparatus 10includes (a) a conduit member 36 connected to the hopper and having adischarging end for permitting a quantity of powder to be movedtherethrough; (b) a conveyor device 40 located at least partially withinthe conduit member for moving the quantity of powder from the hopper ina powder moving direction; and (c) an anti-dribbling nozzle assembly 100for directing a quantity 114 of powder from the conveyor device tocleanly fill the container 16.

[0023] The anti-dribbling nozzle assembly 100 includes a source 64 ofpressurized air, a controller 52 and a nozzle member 34 having a firstend 90 connected to the discharge end of the conduit member 36, a secondand opposite end 92 for dispensing moving powder into the container, anda nozzle wall 96 connecting the first end to the second end. The nozzlewall 96 includes slanted air discharge ports 110 for selectivelydischarging directed pulses 70 of positive pressure air to forciblyremove powder from the nozzle wall 96, thereby enabling clean cutoff ofpowder flowing into the container without post-cutoff dribbling. In oneembodiment as shown, the nozzle wall 96 is porous to air so that uniformrelatively lower pressure air can penetrate from the cavity 62 outsidethe wall 96 through random pores within the wall 96, and in a directionnormal to the axis of the nozzle (FIG. 3) into the inside of the wall96, thereby reducing friction between flowing powder or toner and theinside of the wall.

[0024] As further shown, the slanted air discharge ports 110 are locateduniformly around the nozzle wall 96 and between the first end 90 and thesecond 92 thereof. The slanted air discharge ports 110 are each slantedforwardly relative to a direction of powder flow into the container. Theslanted air discharge ports each form an angle of less than 15 degreeswith the wall. The integration of the slanted or angled air dischargeports 110 into the body or wall 96 of the nozzle member 34 effectivelyprovides an additional and timely force at the end of the cutoff cyclefor pushing out the powder or toner 118 from the nozzle into thecontainer 16.

[0025] Further, with the means 66, 64, for applying positive 68, 70 andnegative 69 air pressure to the wall 96 of the nozzle member 34, themethod of cleanly cutting off filling of the container withoutpost-cutoff dribbling of powder in accordance with the present inventionincludes (a) stopping rotation of the auger 40 for moving powdermaterial from the hopper, and stopping application of uniform continuouspositive pressure 68 to the wall 96 of the nozzle member 34; (b)applying negative pressure 69 to the wall 96; (c) next applyingincreased short bursts 70 of positive air pressure through the slantedair discharge ports 110 in the wall for forcibly removing any powderfrom the nozzle wall; and (c) finally applying negative air pressure 69again to the wall 96 following the step of applying increased shortbursts 70 of positive air pressure. This thereby enables cleanly cuttingoff filling of the container 16 without post-cutoff dribbling of powder.

[0026] As can be seen, there has been provided a method and apparatushave been provided for directing toner from a hopper containing a supplyof toner to fill as well as cleanly cutoff filling of a containerwithout post-cutoff dribbling. The apparatus includes (a) a conduitmember connected to the hopper and having a discharging end forpermitting a toner to be moved therethrough; (b) a conveyor devicelocated at least partially within the conduit member for moving thetoner from the hopper in a toner moving direction towards the container;and (c) an anti-dribbling nozzle device for directing the toner from theconveyor to cleanly fill the container. The anti-dribbling nozzle deviceincludes a source of pressurized air, a controller, and a nozzle memberthat has a first end connected to the discharge end of the conduitmember, a second and opposite end for dispensing moving toner into thecontainer, and a nozzle wall connecting the first end to the secondthereof. The nozzle wall includes slanted air discharging ports fordischarging directed pulses of positive pressure air to forcibly removepowder from the nozzle wall, thereby enabling clean cutoff of powderflowing into the container without post-cutoff dribbling.

[0027] While the embodiment disclosed herein is preferred, it will beappreciated from this teaching that various alternative, modifications,variations or improvements therein may be made by those skilled in theart, which are intended to be encompassed by the following claims:

We claim:
 1. An apparatus for directing powder from a hopper containinga supply of powder to fill as well as cleanly cutoff filling of acontainer without post-cutoff dribbling, the apparatus comprising: (a) aconduit member connected to the hopper and having a discharging end forpermitting a quantity of powder to be moved therethrough; (b) a conveyordevice located at least partially within said conduit member for movingthe quantity of powder from the hopper in a powder moving directiontowards the container; and (c) an anti-dribbling nozzle device fordirecting the powder from said conveyor device to cleanly fill thecontainer, said anti-dribbling nozzle device including a source ofpressurized air, a controller and a nozzle member having a first endconnected to said discharge end of said conduit member, a second andopposite end for dispensing moving powder into the container, and anozzle wall connecting said first end to said second end, said nozzlewall including slanted air discharge ports for selectively dischargingdirected pulses of positive pressure air to forcibly remove powder fromthe nozzle wall, thereby enabling clean cutoff of powder flowing intothe container without post-cutoff dribbling.
 2. The apparatus of claim1, wherein said nozzle wall is porous to air.
 3. The apparatus of claim1, wherein said slanted air discharge ports are located uniformly aroundsaid nozzle member and between said first end and said second thereof.4. The apparatus of claim 1, wherein said controller is connected tosaid source of pressurized air for controlling the application ofpositive and negative air pressure through said slanted air dischargeports in said wall for forcibly removing any powder from said nozzlewall.
 5. The apparatus of claim 1, wherein said controller is connectedto said conveyor device for controlling stopping and starting saidconveyor device to move or halt movement of powder.
 6. The apparatus ofclaim 1, wherein said conveyor device comprises an auger.
 7. Theapparatus of claim 3, wherein said slanted air discharge ports are eachslanted forwardly relative to a direction of powder flow into thecontainer.
 8. The apparatus of claim 5, wherein said controller isadapted for stopping said conveyor device before applying positive andnegative air pressure through said slanted air discharge ports.
 9. Theapparatus of claim 5, wherein said controller includes means for varyingthe application of positive air pressure through said slanted airdischarge ports from uniform positive air pressure to short bursts ofpositive air pressure.
 10. The apparatus of claim 7, wherein saidslanted air discharge ports each form an angle of less than 15 degreeswith said wall.